Microwave popcorn package

ABSTRACT

A microwave popcorn product is provided. The popcorn product includes a package having a popcorn composition therein, the popcorn composition including popcorn kernels, an oil/fat component that can be trans-fat free or low-trans fat, and optional ingredients such as flavorants. At least a portion of the popcorn composition is retained within an internal containment package within the package. The containment package provides containment of any liquid or non-solid components of the popcorn composition. A burst facilitator can be used with the containment pouch; usually, this burst facilitator is water or other form of moisture.

FIELD OF THE INVENTION

The present invention relates to popcorn products and microwave productpackaging. In particular, the invention relates to packages for popcornproducts that include an outer package, a popcorn composition within theouter package, and an internal containment package positioned within theexternal package, the internal containment package configured to retainat least a portion of the popcorn composition.

BACKGROUND

Microwave popcorn popping packages, such as flexible bags, are common. Acommon feature of such bags is that they are generally made from papermaterials that are sufficiently flexible to open or expand convenientlyunder steam pressure, which forms when a popcorn charge therein isexposed to microwave energy in a microwave oven. Also, the packagingmaterials are sufficiently flexible to be formed from a sheet into afolded configuration, for example during a continuous bag-constructionprocess. Popcorn popping bags of this type are described, for example,in U.S. Pat. Nos. 5,044,777; 5,081,330; 5,195,829; 6,049,072; and6,396,036 each of these being incorporated herein by reference. Popcornpopping bags are also described in U.S. Pat. Nos. 4,904,488; 4,973,810;and 4,982,064.

Many microwave popcorn products include a charge of unpopped popcornkernels, fat/oil (i.e., grease) and flavoring (for example, salt) withinthe package. During storage or shipment, especially if the environmentbecomes relatively hot, the material stored within the bag can liquefyand leak through the bag construction. To inhibit such leakage, solidfat/oil products having a relatively high melting or softeningtemperature (typically at least about 90-115° F.) are used. Additionallyor alternatively, some bags are made from expensive materials, such astwo ply papers, glassine paper, or papers having a greaseproof coatingthereon.

Improvements in microwave popcorn packaging are desired.

SUMMARY OF THE INVENTION

In a first aspect of the present invention, a microwave popcorn productis provided, the product having a popcorn composition within an outerpackage. At least a portion of the popcorn composition is containedwithin an internal containment package positioned within the outerpackage. The internal containment package is particularly suited forcontaining and retaining any liquid or non-solid portion of the popcorncomposition therein, that is, any liquid or non-solid components oringredients. Contained within the internal containment package couldalso or alternatively be solid components or ingredients.

The internal containment package has an internal volume to contain atleast a portion of the popcorn composition. The containment package isconstructed to release the portion of the popcorn composition containedtherein during the microwave heating process. Alternately, thecontainment package is constructed to be manually ruptured or burstprior to the microwave heating process. The containment package isconstructed to retain liquid or semi-liquid components therein, reducingthe need for the outer package to use grease-proof paper or otherliquid-proof materials, and, additionally or alternatively, reducing theneed for a package overwrap as a moisture barrier.

A preferred popcorn product includes at least a portion of the oil/fatcomponent of the popcorn composition contained within the internalcontainment package. By containing the oil/fat component within thecontainment package, liquid or non-solid oils and/or fats can be used inthe popcorn product.

In another aspect of the invention, a low-trans fat or no-trans fatmicrowave popcorn product, typically having a liquid oil/fat componentis provided, the liquid oil/fat component being contained and retainedwithin the internal containment package, which is positioned in an outerpackage.

Another preferred microwave popcorn product, according to the presentapplication, a flexible microwavable bag configured for expansion and anedible composition within the bag. The edible composition comprisesunpopped popcorn kernels and an oil/fat component. The oil/fat componentcan include a liquid or non-solid component. An internal containmentpackage is positioned within the expandable bag, with at least a portionof the edible composition contained within the containment package; theinternal containment package is constructed and arranged, due to theincrease of pressure therein during a microwave heating process, toburst and release the portion of the edible composition containedtherein.

Still another preferred microwave popcorn product, according to thepresent application, comprises a package having a microwave interactivesusceptor; and an edible charge having a low trans-fat level, the chargecomprising unpopped popcorn kernels and an oil/fat component.

Yet another preferred microwave popcorn product comprises a rigidmicrowavable tub and an edible composition within the tub. The ediblecomposition comprises unpopped popcorn kernels and an oil/fat component,which, at room temperature, has a liquid portion. Positioned within thetub is an internal containment package with at least a portion of theoil/fat component contained within the containment package, the internalcontainment package constructed and arranged, due to the increase ofpressure therein during a microwave heating process, to burst andrelease the popcorn composition contained therein.

Methods of popping a microwave popcorn product are also disclosed, onepreferred method comprising exposing a popcorn product to microwaveenergy, the popcorn product including an expansion source, increasingthe expansion source in volume by exposure to microwave energy andbursting a containment package to release an oil/fat component and theexpansion source present within the containment package, and popping thepopcorn. The popcorn product includes an expandable package and aninternal containment package within the expandable package. The internalcontainment package is constructed and arranged, due to the increase ofpressure therein during a microwave heating process, to burst andrelease its contents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic top view of a microwaveable popcorn productaccording to the present invention, the product having a compositionincluding unpopped popcorn kernels within a package and a containmentpackage within the package;

FIG. 1A is a schematic cross-sectional view of a first embodiment of thecontainment package of FIG. 1, taken along line 5-5 of FIG. 1;

FIG. 1B is a schematic cross-sectional view of a second embodiment ofthe containment package of FIG. 1, taken along line 5-5 of FIG. 1;

FIG. 2 is a schematic top view of a third embodiment of the containmentpackage of FIG. 1;

FIG. 3 is a schematic top view of a fourth embodiment of the containmentpackage of FIG. 1;

FIG. 4 is a schematic top view of a fifth embodiment of the containmentpackage of FIG. 1;

FIG. 5 is a schematic cross-sectional view of a sixth embodiment of thecontainment package of FIG. 1, taken along line 5-5 of FIG. 1;

FIG. 6 is a schematic top view of a seventh embodiment of thecontainment package of FIG. 1;

FIG. 7 is a schematic top view of an eighth embodiment of thecontainment package of FIG. 1;

FIG. 8 is a schematic top view of a ninth embodiment of the containmentpackage of FIG. 1;

FIG. 9 is a schematic top view of a tenth embodiment of the containmentpackage of FIG. 1;

FIG. 10 is a front perspective view of a package being depicted closedin a storage overwrap and oriented standing on an edge;

FIG. 11 is a schematic top plan view of the package of FIG. 10 showing apositioning of a containment package according to the presentdisclosure, depicted unwrapped and unfolded, as it would be whenpositioned in a microwave oven for cooking;

FIG. 12 is a cross-sectional view taken generally along line 12-12, FIG.11;

FIG. 13A is a schematic, plan view of a package blank showing anadhesive pattern on a first side of the blank, the adhesive used togenerate a package of the arrangement of FIGS. 10-12;

FIG. 13B is a schematic, plan view of the package blank showing anadhesive pattern between two plies of material, the adhesive used tolaminate the two plies together for the arrangement of FIGS. 10-12; and

FIG. 14 is a schematic cross-sectional view of a fiberboard tubincluding a containment package according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

As indicated above, the present disclosure concerns a popcorn productthat includes an outer package and a popcorn composition within thepackage, the composition including unpopped, popcorn kernels, an oil/fatcomponent, and optional flavoring. The present disclosure provides aninternal containment package, positioned within the outer package, inwhich is contained at least a portion of the popcorn composition.

Referring now to the Figures, a first package configuration is provided.FIG. 1 schematically illustrates a popcorn product 10 that includes anouter package 12 having an interior 15. Within interior 15 is thepopcorn composition, which includes but is not limited to unpoppedpopcorn kernels 18 and an oil/fat component 19. Popcorn product 10includes an internal containment package 20 within outer package 12; atleast a portion of the popcorn composition is present within internalcontainment package 20. Preferably and typically, at least anyingredients of the popcorn composition that are liquid or semi-liquid attypical room temperature are contained within containment package 20.Solid ingredients may or may not be contained within containment package20. In FIG. 1, oil/fat component 19 is illustrated within package 20.

The Internal Containment Package

Internal containment package 20 is a package for retaining andcontaining ingredients or components of the popcorn composition prior toa microwave heating process. Specifically, package 20 is a pouch, vial,container, or other such package that has an internal volume. Package20, particularly internal volume 15′, is constructed to contain andretain a portion of the popcorn composition therein. Preferably, package10, particularly volume 15′, is constructed to contain and retainliquid, semi-liquid, or non-solid ingredients or components. Internalcontainment package 20 is non-vented, that is, prior to package 20bursting, there is preferably little or no exchange of air or moisturefrom package 20, other than on a microscopic or atomic level.

Internal containment package 20 at least inhibits leakage of fluidstherethrough or therefrom; that is, package 20 as a whole, including anyside panels, side walls, seals or seams, inhibits leakage. Preferably,package 20, as a whole, is impermeable to liquid leaking therethrough ortherefrom. By use of the term “impermeable to liquid leaking”, andvariations thereof, what is intended is that over a normal product life(generally, a 2 year period) no more than 10% of the total ediblematerial retained by package 20 leaves package 20, either byevaporation, leakage, seepage, etc.

FIG. 1 illustrates a generic internal containment package 20. Thecontainment package 20 of FIG. 1 is illustrated with side edges 20 a, 20b, 20 c, and 20 d. It should be understood that an internal containmentpackage 20, in accordance with the present disclosure, is not requiredto have side edges as illustrated in FIG. 1. Rather, FIG. 1 is a genericdepiction illustrate internal containment package 20 within interior 15of outer package 12. Internal containment package 20 could have a squarearea, circular, triangular, hexagonal, or any such area. Variousconstructions and configurations of internal containment package 20 aredescribed below.

A first construction of containment package 20 is a flexible, generallyflat pouch. FIG. 1A illustrates a cross-sectional view of a flexible,generally flat pouch, which represents internal containment package 20of FIG. 1 taken along line 5-5 of FIG. 1. This containment package 20,specifically, internal containment package 20′, is formed from a firstsidewall 11 and a second sidewall 13, which defines interior volume 15′of containment package 20′. Sidewalls 11, 13 are sealed together atedges 20 a, 20 b. This seal may be made by any suitable means, includingheat-sealing, ultrasonic sealing, and by the use of an adhesive. In avariation, package 20′ can have a fold present at one of edges 20 a, 20b and can be sealed together at the other one of edges 20 a, 20 b. Atleast one of edges 20 a, 20 b, 20 c, 20 d includes a region that willburst or release during microwave heating, so that the contents withininterior volume 15′ are released. This release or burst region isfurther described below.

Examples of suitable materials for sidewalls 11, 13 of internalcontainment package 20 include polymeric film (e.g., polyethylene,polypropylene, cellophane, mylar, silicon-oxide coated films,aluminum-oxide coated films, polyester, and nylon), metal foil,metallized polymeric film, treated papers, and laminated productsthereof. The material should be such that leak-proof seals can be madebetween sidewalls 11, 13. One preferred material for sidewalls 11, 13 is150 gauge OL film commercially available from DuPont Teijin Films. Thesematerials, and the resulting containment package 20′, are fairlyflexible. Additional details regarding internal containment package 20′,and methods of making package 20′, are provided below.

A second construction of containment package 20 is a fairly rigidcontainer, having a measurable length, width and thickness. FIG. 1Billustrates a cross-sectional side view of a rigid, generallythree-dimensional containment package 20″, which represents internalcontainment package 20 of FIG. 1, taken along line 5-5 of FIG. 1. Thiscontainment package 20, specifically, internal containment package 20″,is formed from a topwall 11′, a base 13′, a first edge wall 7 at edge 20a and a second edge wall 9 at edge 20 b, which together define internalvolume 15′ of containment package 10″. Internal containment package 20″can be cylindrical, cubic, block-like, spherical or semi-spherical, orhave any other three dimensional shape. Internal containment package 20″is typically made from less flexible, more rigid materials than theflexible, polymeric materials disclosed above for containment package20′. Examples of suitable materials for containment package 20″ includewax, cellulose, gelatin, and the like. Preferably these materials arenon-toxic and are foodgrade. Internal containment package 20″ isparticularly suitable as a manual-burst containment package.

Containment package 20 (whether containment package 20′ or containmentpackage 20″) is positioned inside package 12. Internal containmentpackage 20 can be attached or secured to an interior surface, such as aside panel or an end seam of package 12. An adhesive can be used tosecure package 20 to an interior surface. Additionally or alternately,package 20 can be sealed or attached into an end or side seam of package12 during manufacture of package 12. Alternately, package 20 can beunattached to an interior surface of outer package 12. An internalpackage 20 that is initially unattached or unsecured to interior 15 ofouter package 12 could include a heat activated adhesive thereon, sothat during microwave heating, internal package 20 would adhere tointerior 15.

Containment package 20 is preferably positioned in close proximity topopcorn kernels 18, and preferably the entire containment package 20 iswithin interior 15, although in some designs a portion of containmentpackage 20 may be present on the exterior of package 15.

As stated above, containment package 20 can contain and retain any orall of unpopped popcorn kernels 18, oil/fat component 19, flavors,additives, and any other component of the popcorn composition.

Popcorn Kernels

Unpopped popcorn kernels 18 are any hulled or dehulled popcorn kernelknown for use in microwave popcorn products. The kernels may be large,medium, small, white, yellow, flavored, or any type of available kernel.Usually, the popcorn kernels have an internal moisture level of about11-16%.

Oil/Fat Component

Oil/fat component 19 facilitates the even distribution of heat topopcorn kernels 18 prior to and during popping of kernels 18. Oil/fatcomponent 19 further facilitates the distribution of flavor amongpopcorn kernels 18 by splashing, pouring, spraying, blowing or otherwisedistributing itself and any flavor over the popped popcorn flakes.Oil/fat component 19, when present in the popcorn composition, isgenerally a separable component from kernels 18. That is, oil/fatcomponent 19 is not appreciably absorbed by or present within theinterior of kernels 18.

Oil/fat component 19 refers to materials that are primarily tri-fattyacid esters of glycerol. Fat is a natural lipid material that is mainlysolid at room temperature. Oil is similar to fat, but is liquid at roomtemperature. The term “oil/fat component” is meant to refer to oil(s),fat(s) (natural or modified) and any mixtures thereof. The “oil/fatcomponent” may be a solid, liquid, or semi-solid at room temperature.Many forms of oil/fat component 19 are substantially solid at roomtemperature prior to the popping process, and readily melt during themicrowave popcorn popping process. When the terms “liquid”,“semi-solid”, “non-solid” and other such terms are used, what isintended is an oil/fat component which, at room temperature, is flowableand does not hold a third dimensional shape if not retained by a mold orother structure for one hour. That is, a liquid, semi-solid or non-solidoil/fat component 19 will slump or otherwise loose a formed shape withinone hour.

Preferred oils for use in oil/fat component 19 include non-hydrogenatedand/or partially hydrogenated vegetable oils. Suitable oils includethose obtained from sunflower oil, safflower oil, rapeseed oil,cottonseed oil, maize oil, linseed oil, groundnut oil, and soybean oil.Other suitable oils include nut oils (such as almond, brazil nut,cashew, coconut, hazelnut, pecan, peanut, and walnut), olive oil, palmoil, sesame oil, and flaxseed oil. Non-fat oils, such as olestra (e.g.,commercially available under the trade name Olean) are also suitable foruse.

The amount of oil/fat 19 within popcorn product 10, in relation to theunpopped popcorn kernels, is no more than about 50 wt-%, and istypically no more than about 40 wt-%. The amount of oil/fat 19 isusually at least 1 wt-% and typically at least 5 wt-%.

Flavorants

Popcorn product 10 of the present invention can include any suitabletype of flavorant or flavoring, depending on the specificcharacteristics and/or flavor the final product is to have. In typicalapplications, product 10 will include various flavorants, colorants andother adjuvants in the popcorn composition. Typical components thatmight be included in the popcorn composition are salt and butter flavor.Other suitable flavors include sweet, sour, sugary, savory, tart, spicy,fruity or any other flavor. Examples of specific flavors include, butare not limited to: butter, cheese(s), sour cream & chive, dill, herb,onion, garlic, jalapeno, bacon, pizza, tomato, salt & vinegar, barbecue,taco, cinnamon, nutmeg, hickory and smoke. The flavorants may be presentas a liquid or a solid, and may be contained within a cell of internalcontainment package 20 or be external to internal containment package 20within interior 15 of outer package 12. It should be understood that theamount of flavorant present in the popcorn composition prior to poppingand in the popped product will largely depend on the specific flavorantused.

Expansion Source

In one design of containment package 20, in order to release theingredients or components contained within package 20, containmentpackage 20 includes an expansion source therein that bursts or openspackage 20. This expansion source is generally a moisture source such asliquid water, although moisture present in other ingredients, such asthe unpopped popcorn 18, is also suitable. An amount of moisture orother expansion source is desired within containment package 20 in orderto burst or otherwise penetrate containment package 20. Most oil/fatcompositions do not appreciably expand in volume during microwaveheating, however, emulsions or other oil/fat components that includewater therein, such as a margarine emulsion, will release water uponheating, allowing steam to expand and burst containment. Water expandsat least about 1200 times the volume (at the same pressure) as it heatsfrom room temperature (about 20° C.) to its boiling temperature (100°C.).

The moisture source present within internal containment package 20sufficiently expands to burst package 20 usually within about 15-45seconds after the initiation of microwave energy from a conventionalresidential microwave oven, usually 800-1200 watts. It is preferred thatinternal containment package 20 bursts prior to popcorn 18 popping.

Referring to FIGS. 2 through 9, various embodiments of containmentpackage 20 are illustrated. FIGS. 2 through 6 illustrate multiple cellor multiple chamber containment packages and FIGS. 7 through 9illustrate single cell or chamber containment packages. The embodimentsillustrated in FIGS. 2 through 9 are generally flexible, fairly flatpackages, made from polymeric film; these embodiments are similar tocontainment package 20′ in FIG. 1A.

Multiple Cell

Containment package 20 of FIG. 2 is specifically containment package 21having a first cell 21 a and a second cell 21 b. First cell 21 a retainsan expansion source, water 17, and optionally but preferably salt, andsecond cell 21 b retains oil/fat 19.

Containment package 20 of FIG. 3 is specifically containment package 22having a first cell 22 a and a second cell 22 b. Similar to containmentpackage 21 of FIG. 2, first cell 22 a of FIG. 3 retains a volume ofwater 17, and optionally but preferably salt, and second cell 22 bretains oil/fat 19.

Packages 21, 22 differ in that containment package 21 of FIG. 2 isconstructed so that each of first cell 21 a and second cell 21 bindividually bursts/through a side edge of package 21. First cell 21 ahas a first burst region 31 a and second cell 21 b has a second burstregion 31 b. Each of burst regions 31 a, 31 b extends from cells 21 a,21 b, respectively, and, when burst or otherwise ruptured, provides apassage from cell 21 a, 21 b to the exterior of containment package 21through side edge 20 c. In the embodiment of FIG. 2, increased pressurewithin cell 21 a will burst both regions 31 a and 31 b.

Burst regions 31 a, 31 b, and all others described herein, are regionswithin containment package 20 that are a weakness or other structure ofpackage 20 designed to burst upon the build-up of pressure within thecell and release the pressure from the interior 15′. The burst regionmay be a weaker seal at a side edge, such as at edge 20 c, a perforatedarea, a slit, a notch, or other such structure that weakens thestructure and creates a weak point.

In package 22 illustrated in FIG. 3, first cell 22 a has a first burstregion 32 a and second cell 22 b has a second burst region 32 b. Unlikethe configuration of package 21 of FIG. 2, burst region 32 a is designedso that the contents of first cell 22 a, water 17, bursts into secondcell 22 b. The mix of water 17 and oil/fat 19 then bursts from secondcell 22 b via region 32 b through side edge 20 a. The rupturing of firstburst region 32 a and second burst region 32 b may be simultaneous orsequential.

As discussed above, containment package 21 of FIG. 2 and containmentpackage 22 of FIG. 3 include expansion source water 17, and optionallybut preferably salt, in first cell 21 a, 22 a and oil/fat 19 in secondcell 21 b, 22 b. Popcorn product 10, such as that illustrated in FIG. 1,that incorporates either of package 21 or package 22 would include acharge of popcorn 18 in volume 15 external to package 21, 22. Thus,during the microwave heating of a popcorn product having either package21 or package 22, containment package 21, 22 would burst, providingoil/fat 19 to cover popcorn 18 and facilitate its popping. Water 17 istypically released as steam from containment package 21, 22, althoughsome liquid water 17 may be splashed onto popcorn 18.

Another embodiment of a multiple cell containment package 20 isillustrated in FIG. 4. Specifically, FIG. 4 shows a containment package23 having a first cell 23 a and a second cell 23 b. Containment package23 has a first burst region 33 a extending from first cell 23 a tosecond cell 23 b, and a second burst region 33 b extending from secondcell 23 b to side wall 20 a.

Similar to containment package 22 of FIG. 3, first cell 23 a of FIG. 4retains water 17, and optionally but preferably salt, therein, andsecond cell 23 b retains oil/fat 19 therein. Second cell 23 b additionalincludes a charge of popcorn 18 therein. In alternate constructions,popcorn 18, with or without some amount of oil/fat 19, may instead bepresent in first cell 23 a, with additional oil/fat 19 in second cell 23b. In such a construction, the moisture within popcorn 18 provides themoisture needed to rupture first cell 23 a. Additional popcorn 18 may ormay not be present within interior 15 of package 12.

FIG. 5 illustrates a variation of multiple cell containment packages 21,22 and 23 described above. FIG. 5 illustrates a multiple cellcontainment package often referred to as a “sandwich” containmentpackage. That is, rather than the first cell and the second cell beingpositioned next to each other, as in packages 21, 22 and 23, in theembodiments of FIG. 5, the first cell and second cell are stacked.Additional details are found below and in conjunction with FIG. 5.

Specifically, containment package 20 of FIG. 5 is a containment package24 having a first cell 24 a and a second cell 24 b. First cell 24 acontains water 17, and optionally and preferably salt, and second cell24 b contains oil/fat 19.

First cell 24 a and second cell 24 b are defined by cell walls 41, 43and 45; specifically, first cell 24 a is defined by walls 41 and 45 andsecond cell 24 b is defined by walls 43 and 45. Walls 41, 43, 45 meetand are sealed at edges 20 a and 20 b. Containment package 24 has afirst burst region 34 a extending from first cell 24 a and a secondburst region 34 b extending from second cell 24 b. Each burst region 34a, 34 b, located at edge 20 b, is designed to burst or release betweenthe respective cell walls. That is, first burst region 34 a will burstthe seal between walls 41 and 45, and second burst region 34 b willburst the seal between walls 43 and 45. Burst regions 34 a, 34 b aresimilar to burst regions 31 a, 31 b, in that the regions are structuredso that the build-up of pressure within cell 24 a will burst bothregions 34 a and 34 b.

In FIG. 6, yet another variation of a multiple cell containment package20 is illustrated, specifically internal containment package 25 having afirst cell 25 a within a second cell 25 b. First cell 25 a may befree-floating or unsecured within second cell 25 b, or first cell 25 amay be fixed or secured within second cell 25 b. A secured first cell 25a can share a side wall with second cell 25 b. First cell 25 a,positioned within second cell 25 b, contains water 17 and optionally andpreferably salt, and second cell 25 b contains oil/fat 19. First cell 25a has first burst region 35 a, and second cell 25 b has second burstregion 35 b. Build up of pressure within first cell 25 a will causeburst region 35 a to release, thus increasing pressure in second cell 25b and thus causing burst region 35 b to break. Second burst region 35 bmay rupture simultaneously with or subsequent to first burst region 35a.

Single Cell

Referring now to FIGS. 7 through 9, containment packages 20 having asingle cell or chamber are illustrated. Specifically, FIG. 7 showscontainment package 26, FIG. 8 shows containment package 27, and FIG. 9shows containment package 28. Similar to containment packages 21, 22,23, 24 and 25, described above, containment packages 26, 27 and 28 ofFIGS. 7-9 retain oil/fat 19 and a moisture source, except, however,containment packages 26, 27 and 28 of FIGS. 7-9 have a single cell forretaining both the oil/fat and the moisture source.

Containment package 26 of FIG. 7 has cell 26 a which retains water 17and optionally but preferably salt, and oil/fat 19 therein. A burstregion 36 extends from cell 26 a to side edge 20 c. Water 17 may beintimately mixed with oil/fat 19, for example, as an emulsion. In mostconstructions, water 17 and oil/fat 19 are non-miscible, and an emulsionis preferred.

In a variation of containment package 26, oil/fat 19 can be presentwithin cell 26 a with no water 17 present therein. With no expansionsource present, cell 26 a will typically not rupture withoutintervention, which can be provided by the consumer. That is,immediately prior to placing the popcorn package in the microwave oven,the consumer can manually rupture the containment package 26, forexample by hand pressure, to release oil/fat 19. It is understood thatany containment package 20 can be manually ruptured if desired.

Containment package 27 of FIG. 8 is similar to the illustratedcontainment package 26 of FIG. 7 in that it has a cell 27 a and a burstregion 37 extending from cell 27 a to side edge 20 c, except thatpackage 27 of FIG. 8 retains a modified oil/fat product 19′, such as anemulsion, which incorporates in it a moisture source. There is no liquidwater within cell 27 a.

Likewise, containment package 28 of FIG. 9 is similar to package 26 ofFIG. 8 by having a cell 28 a and a burst region 38 extended from cell 28a to side edge 20 c. Containment package 28 includes no liquid waterwithin cell 28 a; instead, cell 28 a retains oil/fat 19 and a charge ofpopcorn kernels 18. Popcorn 18 within cell 28 a provides sufficientmoisture to have cell 28 a expand and burst.

The various containment packages 20 illustrated and described aboveprovide a secure location for ingredients that are usually liquid orotherwise flowable at usual room temperatures, so that the liquid doesnot leak or otherwise cause a mess. Ingredients that are usually liquidat room temperatures include fats and oils. Although only water 17,popcorn 18 and oil/fat 19, have been described as being present withincontainment package 20, flavorants or other adjuvants could also beretained and contained within package 20, particularly any liquidflavorants or other adjuvants.

Expansion Source Revisited

As described above, it is desired to have an expansion source present tofacilitate opening or bursting of containment package 20 to releasefat/oil 19 retained inside. Typically, this expansion source is amoisture source, such as liquid water.

The amount of moisture is such so that the volume increase in themoisture caused by microwave heating is sufficient to burst or otherwisebreak the seal or the burst region on the cell in which water 17 orother moisture source is contained. It is understood that the specificamount of moisture will depend on the size of the cell, the presence ofother elements within the cell, elements such as oil/fat 19, popcorn 18,flavorants, and even air. For preferred popcorn products having about 99grams of edible components, about 1-2 grams of saline water (having6.25% wt-NaCl) as expansion source are used.

For a multiple cell containment package 20, where oil/fat 19 and water17 are contained separately, the amount of water 17, as a ratio tooil/fat 19, is at least 1:250. The amount of water 17, as a ratio tooil/fat 19 is no greater than 1:5, and often no greater than 1:6.25.Typically the ratio of water 17 to oil/fat 19 is 1:50 to 1:15. A ratioof 1:16.7 water:oil/fat is one preferred ratio.

For a single cell containment package 20, where the oil/fat 19 and water17 are present in the same cell, the ratio of water 17 to oil/fat 19 isat least 1:250. The amount of water 17, as a ratio to oil/fat 19 is nogreater than 1:5, and often no greater than 1:6.25. Typically the ratioof water 17 to oil/fat 19 is 1:50 to 1:15. A ratio of 1:16.7water:oil/fat is one preferred ratio.

For embodiments having a modified oil/fat 19′ such as an emulsion ofwater in oil/fat, the amount of water 17 in oil/fat 19′ is at least0.05% by weight; the amount of water in oil/fat 19′ is generally nogreater than 25% by weight. In some embodiments, it is possible to use a“reversed-emulsion”, having oil/fat dispersed within an aqueoussolution, and thus having more than 25% by weight water content.

In the “manual burst” package 20 described above, an embodiment of whichis illustrated in FIG. 1B as internal containment package 20″, nomoisture would be necessary to release oil/fat 19, as package 20 isruptured manually by the consumer or by other physical means. If themanual burst package 20 is generally flexible application of pressurefor example rolling the palm of the hand is usually sufficient to burstpackage 20. A rigid manual burst package 20 could be manually snapped orcracked.

The unpopped popcorn kernels 18 are also a good source of moisture.Popcorn kernels 18 usually have a moisture content of about 11-16%;depending on the amount of popcorn 18 and the size of the cell, theexpansion of this moisture is generally sufficient to burst the seal onthe cell.

Vaporization of the water, and thus steam, can be generated more quicklyby the addition of salt to the water. By use of the term “salt”, what isintended is edible anionic salts of chloride and iodide, most commonlysodium chloride. It is preferred to have some salt present in water 17.If present, the amount of salt added to the water is typically at least0.5 part per 100 parts water, to make about a 0.5% saline solution .Typically, the amount of salt added to the water is no greater thanabout 15 parts salt per 100 parts water (about a 13% saline solution)and more typically, the amount of salt added to the water is not greaterthan about 10 parts per 100 parts water (about a 9% saline solution). Asuitable and common range of saltwater includes 1:100 to 5:100 (about 1%saline to about 5% saline). The salt added to the water will providesome degree of flavoring to the popped popcorn. However in most cases,additional salt will be present in other locations within product 10,such as with fat/oil 19 or with popcorn kernels 18.

The salt used is typically sodium chloride (common table salt or seasalt), although other salts such as potassium chloride, potassiumiodide, sodium iodide, calcium chloride, may be suitable. Any size ofsalt may be used. Common sizes of salt include those known as table saltor flour salt.

The following table provides a definition of preferred popcorncompositions, prior to being popped, based on the entire edible product.

Most Typical Preferred Preferred Ingredient wt-% wt-% wt-% One Examplegrams Unpopped ≧50 wt-% 60-85 wt-% 64-70 wt-%  69.5 grams popcornkernels Oil/Fat ≦50 wt-% ≦30 wt-% 24-30 wt-% 27.05 grams Saline solution0.1-10 wt-%  0.5-5 wt-%  1-2 wt %   1 gram (6.25 wt-% NaCl*) Other  ≦5wt-%  ≦3 wt-%  2.75 grams Flavorants *The 6.25 wt-% saline solution wasmade by combining 15 grams water with 1 gram NaCl.

No or Low Trans-Fat Popcorn Product

As stated, containment package 20 provides a suitable and convenientpackage for retaining and containing any and all liquid ingredients orcomponents of the popcorn composition. Many oil/fats 19, particularlythose having no-trans fat or low-levels of trans fat, are liquid at roomtemperature. Trans-fat is also commonly referred to as “trans-fattyacids” or variations thereof. Examples of oils and/or fats that can beconsidered to be trans-fat free or low-trans fat include sunflower oil,canola oil, corn oil, olive oil, soy oil, peanut oil, palm oil, andcoconut oil.

Because typical trans-fat free oils/fats are liquid or non-solid at roomtemperature, the trans-fat free oils/fats are preferably retained withincontainment package 20 as oil/fat 19 or as oil/fat 19′. The popcornproduct of the present invention could include a source of oil/fat thatis not contained within containment package 20, but is present withininterior 15 of package 12. Typically, any oil/fat present outside ofcontainment package 20 is solid or semi-solid at room temperature.

For this application, a popcorn product having “no trans-fat” or being“trans-fat free” has no more than 5 grams of trans-fat per 100 grams ofedible product. A product having “low trans-fat” has no more than 10grams of trans-fat per 100 grams of edible product.

In a preferred product configuration, the entire edible component,including oil/fat 19 within package 20 and any other oil/fat, includesno more than 5 wt-% of trans-fat, preferably no more than 1.5 wt-% oftrans-fat. Any trans-fat may be present within containment package 20,either in the same cell as the no trans-fat or low trans-fat or in aseparate cell, or, a trans-fat may be present outside of package 20. Itmay be desirable to add an amount of trans-fat, such as partiallyhydrogenated soybean oil, to the popcorn product, for example, to modifythe taste of the popped product, to contain additional salt and/orflavors, or to retain a product load on the susceptor. It is preferred,however, that the amount of trans-fat is no more than about 10 wt-% ofthe entire oil/fat component, preferably no more than about 5 wt-%.

The following table provides a definition of preferred no trans-fat orlow trans-fat popcorn compositions, prior to being popped, based on theentire edible product.

Typical Preferred Most Preferred One Example Ingredient wt-% wt-% wt-%grams Unpopped ≧50 wt-% 60-85 wt-% 64-70 69.5 grams popcorn kernelsTrans-fat <50 wt-% ≦30 wt-% 24-30 wt-% 24.8 grams Free Oil/Fat TransOil/Fat ≦5 wt-% ≦2 wt-% ≦1.5 wt-%,  1.5 grams even more pref. ≦1 wt-%Saline 0.1-10 wt-% 0.5-5 wt-% 2-5 wt %   1 gram solution (6.25 wt-%NaCl*) Other ≦5 wt-% ≦3 wt-% 2.75 grams Flavorants *The 6.25 wt-% salinesolution was made by combining 15 grams water with 1 gram NaCl.

The Containment Package, Revisited

Returning to containment package 20, as described above, package 20 is amechanism for providing a retainer, receptacle, or other container toretain liquid components, such as oil/fat 19, including no or lowtrans-fat substance oil/fat 19, so that under typical storage and usageconditions of popcorn product 10, these liquid components do not leakfrom product 10.

Typically, containment package 20 is a fairly two dimensional or flatpouch, made from a material that inhibits water 17, oil/fat 19, and anyother ingredients or components from seeping therethrough, preferably,eliminates seeping therethrough. Examples of suitable materials forpackage 20 include polymeric film (e.g., polyethylene, polypropylene,mylar, silicon oxide coated films, aluminum-oxide coated films, othermetallized films, polyester, nylon, or other poly resin materials),metal foil, treated papers, and laminated products thereof. The materialshould be such that leak-proof seals can be made between plies of thematerial. Examples of suitable sealing methods include adhesives, heatsealing (e.g., sealing under heat and pressure), or ultrasonic sealing.

Containment package 20 can be made by any number of methods. Onepreferred method for making package 20 is to overlap two sheets ofmaterial, such as polymeric material, heat seal three sides (e.g., sideedges 20 a, 20 b, 20 d of FIG. 1) and any internal seals between cells,fill the cell(s), and seal the last side (e.g., side edge 20 c). Anotherpreferred method is to fold a sheet of polymeric material, the foldforming a first side, such as side edge 20 d, heat sealing side edges 20a, 20 b and any internal seals, filling the cell(s), and sealing sideedge 20 c. Yet another method is to use a tube of material (the tubeforming side edges 20 a, 20 b), sealing side edge 20 d and any internalseals, filling the cell(s), and sealing side edge 20 c.

The overall size of containment package 20 should be such thatadequately retains the cell(s) and provides an adequate seal around thecell(s). For example, for some packages 20, a heat seal ⅝ inch thick(about 1.6 cm thick) is provided on all sides of package 20.

The size of the containment package 20 cells should be adequate tocontain the amount of oil/fat 19, water 17, popcorn 18, and any otheringredients that might be retained within package 20. For a dual cellpackage, such as packages 21, 22, 23 of FIGS. 2, 3 and 4, each celltypically has a volume of at least 2 cm³, prior to expansion. Thespecific volume of the cell depends on its contents. For example, if 22grams of oil/fat 19 are retained in a cell, the cell volume ispreferably about 25 to 60 cm³. For 1.5 grams of water or saline 17, thecell volume is preferably about 2 to 20 cm³. If popcorn 18 is presentwithin the cell, the cell should be sufficiently large to retain all ofthe popcorn 18, oil/fat 19, and other ingredients.

Containment package 20 preferably includes burst region 31 a, 31 b, 32a, 32 b, etc., as described above. These burst regions may be a weaknessin the seal between or around the cells, or may be a notch, slit,perforation, or other weakness formed within the seal. The function ofthe burst region is to direct where package 20 will burst. It should beunderstood that the burst region could be positioned in any side edge ofpackage 20. An example of a suitable burst region is a triangular notchcut into the seal. A slit in the seal is also suitable as a burstregion. Usually, the distance that the burst region extends into theseal is no more than 90% of the width of the seal, typically no morethan about 75%. Preferably, at least 0.25 inch of the seal is leftwithout a burst region. The burst region depth or length could be a lowas 0.062 inch.

A popcorn composition and containment package 20, with at least aportion of the popcorn composition retained within package 20, ispositioned within a package. In the embodiment illustrated in FIG. 1,unpopped popcorn kernels 18 are present in interior 15 outside ofpackage 20 and oil/fat is present within containment package 20. Package12 can be any type of suitable microwave popcorn package such as anexpandable bag or a tub. Containment package 20 is positioned withininterior 15 of package 12, positioned to minimize interference withexpansion of package 12 during microwave heating. Preferably, package 20is attached or secured to package 12 rather than freely positionedwithin interior 15. By use of the terms “attached”, “secured”, or thelike, what is intended is that at least a portion of the internalcontainment package 20 is fixed to and immovable in respect to interior15 of outer package 12. The terms “unattached”, “unsecured”, freelypositioned” and the like, are intended to mean that the internalcontainment package is movable in respect to interior 15 of outerpackage 12.

Additionally, containment package 20 is preferably positioned, whethersecured or unsecured, in package 12 so that popcorn 18 is positioned inclose proximity to any microwave interactive susceptor in package 12.Depending on the specific construction of package 20 and the componentstherein, typically, popcorn 18 is between the susceptor and containmentpackage 20, although in embodiments such as a single cell internalcontainment package having popcorn kernels 18 therein, popcorn 18 maynot be between the susceptor and internal containment package 20, butwill be within package 20, as described above. It should be understoodthat internal containment package 20 could be positioned anywhere ininterior 15 of outer package 12.

Containment package 20 is typically attached to package 12 during theproduction of package 12. Examples of specific, suitable packages 12 aredescribed below.

Packages for Popcorn Products

As discussed above, the unpopped, microwaveable popcorn composition isprovided in package 12 to form popcorn product 10. In general, such apackage can be an expandable, flexibe bag, such as in accord with U.S.Pat. Nos. 5,044,777 (Watkins et al.), 5,690,853 (Jackson et al.),5,650,084 (Bley) or. 6,049,072 (Olson et al.), or a rigid tub, such asin accord with U.S. Pat. Nos. 5,008,024 (Watkins) or 5,834,046 (Turpinet al.), each of these which is incorporated herein by reference. Intypical preferred packages, the microwave package contains a microwaveinteractive construction or susceptor, to enhance the popping operation.Such susceptors are described for example in U.S. Pat. Nos. 5,149,396(Wilson); 5,175,031 (Ochocki) 5,338,911 (Brandenberg et al.); and5,285,040 (Brandenberg et al.), all incorporated herein by reference.

Attention is now directed to FIGS. 10-14. In FIG. 10, a flexiblemicrowave popcorn bag 101 is depicted stored or oriented substantiallyvertically. Bag 101 is depicted in a trifold configuration 102, includedwith an overwrap 103 for storage. In FIG. 11, a top plan view of popcornbag 101 is shown schematically in an unfolded configuration and orientedmuch as it would be when positioned in a microwave oven for popping ofthe popcorn charge contained therein, but before expansion of thepackage. The term “flexible” is meant to refer to a bag and bag materialwhich is not so stiff or rigid as to undesirably interfere with bagexpansion during use. Alternately stated, the term is used to refer to abag that can be readily folded and unfolded.

In FIG. 11, lines 111 and 112 indicate fold lines which define centralregion 113 of the arrangement. Inside the bag in central region 113,unpopped popcorn 18 and containment package 20 would generally bepositioned in orientation above a portion of the bag in which amicrowave interactive construction (susceptor) is positioned. The term“microwave interactive” is meant to refer to a material that becomes hotupon exposure to microwave energy in a microwave oven. Typical microwaveinteractive constructions comprise a metallized polymeric component (forexample, aluminized products) positioned in bag 101.

During the popping operation, any expansion source, such as water,absorbs microwave energy and expands, thus bursting the cell(s) ofcontainment package 20 and releasing oil/fat 19. This moisture alsogenerates sufficient steam and heat for popping and for expansion of bag101. In addition, the microwave interactive material also absorbsmicrowave energy and dissipates heat to the popcorn composition.

Attention is now directed to FIG. 12, a cross-section taken generallyalong line 12-12 of FIG. 11. In FIG. 12 it can be seen that bag 101generally comprises a double wall (or two-ply 146, 147) configurationdefining first and second opposite panels 120 and 121 joined by firstand second side gussets 122 and 123. Gussets 122 and 123 generallyseparate popcorn bag 101 into first and second expandable tubes 128 and129. Popcorn charge 118 is substantially positioned and substantiallyretained within tube 128. Underneath popcorn charge 118, bag 101includes a microwave interactive construction or susceptor 145. Incertain arrangements, such as the one shown in FIG. 10, susceptor 145 ispositioned between plies 146, 147 from which flexible bag 101 is folded.Containment package 20 is positioned within expandable tube 129,preferably adhered to ply 147. Thus, the construction shown in FIG. 12has popcorn charge 118 positioned between susceptor 145 and containmentpackage 20.

In FIG. 13A, a panel 160 is shown; panel 160 is a blank or sheet offlexible material from which bag 101 is folded. Panel 160 includesvarious sealant fields 161, 162, 163 thereon, shown in dot pattern,which provide desired features in the resulting folded bag 101. Sealantfields 161, 162 provide a package, as is described in U.S. Pat. No.5,650,084, having end gussets. Sealant field 163 is used to adhere amicrowave susceptor to panel 160. In one embodiment, this sealant field163 is about 6.5 inches by 5.625 inches.

Panel 160 is typically formed from two plies of paper laminatedtogether, as illustrated in FIG. 12 with plies 146, 147. A preferredlamination adhesive pattern is illustrated in FIG. 13B on panel 160; itshould be understood that the adhesive pattern illustrated in FIG. 13Bis present between two plies, which are then used to form panel 160described above having sealant fields 161, 162, 163. Various sealantfields are present on panel 160 in FIG. 13B, particularly, sealantfields 165, 167, 169. Sealant field 165 is present at the center ofpanel 160 and includes a field of continuous coverage of adhesive. Themicrowave interactive susceptor is typically present within the area offield 165. Sealant fields 167, which also are areas of continuouscoverage of adhesive, are present at the ends of panel 160. Sealantfields 169 include crossing lines of adhesive, having portions of panel160 uncoated with adhesive. Approximately 55% of the surface of panel160 is covered by adhesive.

An outside border 170, defined at least by sealant fields 167 and thearea designated by broken lines 172, is positioned at the perimeter ofpanel 160. Border 170, in preferred arrangements, is about 0.625 to1.125 inches wide. Outside border 170 comprises a region completelycovered by adhesive. In the embodiment illustrated in FIG. 13B, theportion of sealant fields 167 within border 170 forms a regioncompletely covered by adhesive. Additionally, the portion of sealantfield 165 within border 170 forms a region completely covered byadhesive. The portion of sealant field 169 within border 170 forms aregion having a contiguous region of adhesive.

In alternate embodiments, popcorn product 10 can have a rigid tubconfiguration, as for example shown schematically in FIG. 14 andcharacterized in U.S. Pat. No. 5,384,024, incorporated herein byreference. A cross-section of such a tub 200 is depicted in FIG. 14,containing popcorn charge 218, a microwave interactive susceptor 210,and internal containment package 20. Popcorn charge 218 is positioned inproximity to susceptor 210 and between susceptor 210 and containmentpackage 20. Such tubs are generally made from a paperboard or fiberboardmaterial, with a flexible film used for a cover. In general, with sucharrangements, a cover 205 expands or balloons under the heat and steamproduced during the popcorn popping operation. Containment package 20,in this embodiment, is attached to cover 205. Tub 200 has an inverted,rigid conical sidewall construction 215 that facilitates nesting andstacking, facilitates popping of charge 218, and provides a bowl afterpopping and opening/removal of cover 205.

The invention will be further described and illustrated in the exampleswhich follow. The examples are illustrative of the invention and shouldnot be construed as limiting the scope to their details. All parts,percentages, ratios, etc. are by weight unless otherwise specified.

EXAMPLE 1

Example 1 was a popcorn product incorporating a single cell containmentpouch for containment of trans-fat free oil. Multiple (approximately 30)containment pouches were made and tested using the following materialsand procedures. The materials used for Example 1 were as follows:

pre-made microwave popcorn bags (such as those shown in FIGS. 1-4 ofU.S. Pat. No. 6,049,072, except having the adhesive pattern illustratedin FIG. 13A of this application and the lamination adhesive patternillustrated in FIG. 13B)—unsealed at both ends;

150 gauge sealable “OL Mylar” film—10 inch wide rolls—commerciallyavailable from DuPont Teijin;

“Duracet” heat activated glue;

margarine type emulsion containing water, salt, and one or both of cornoil, and NuSun mid-oleic acid sunflower oil, the emulsion commerciallyavailable from various oil suppliers;

partially hydrogenated/winterized soybean oil,

powdered salt, mesh size 200 (75 microns);

partially hydrogenated soybean oil; and

un-popped kernels of microwave popcorn.

Containment pouches were made by cutting the mylar film into rectangularpieces measuring 5.0 inches×5.5 inches (12.7 cm×14 cm). Two pieces ofthe film were stacked on each other, with the sealant layer surfacesfacing each other. The two width (shorter, 5.0 inch (12.7 cm)) sides andone of the length (longer, 5.5 inch (14 cm)) sides of the pieces of filmwere sealed with the heat sealer (model 12-ASL heat sealer from SencorpPackages Inc). The seals were between about 0.5 inch (1.3 cm) and 0.625inch (1.6 cm) wide. The sealer was set for 0.6 seconds, 240° F. (115°C.), and with a seal bar pressure of 80 PSI.

While holding the pouch open, 22.8 grams of the margarine-type emulsionwere placed into the pouch; care was taken to not contaminate thefourth, future seal area with the emulsion. Next, the fourth seal on thepouch was made using the same technique as the other three seals. With ascissors, a 0.25 inch (0.64 cm) slit was made in the center of the last(length side) seal. A thin coating of Duracet heat activated glue wasapplied to both sides of the non-slitted length seal.

After the Duracet glue was dry, the containment pouch was inserted intothe bottom end of the pre-made bag so that the long (5.5 inch (14 cm))side of the pouch was parallel with the end of the bag. The side of thepouch with the slit was positioned towards the center of the bag, andthe side with the Duracet was positioned near the bottom seal area ofthe bag. The containment pouch was positioned between the top layer ofthe bag (the side without the susceptor) and the gussets, with the edgeof the pouch centered in the bottom seal area of the bag. The bag endwas sealed with the heat sealer, thus sealing the containment pouch inits position. The sealer was set for 0.6 seconds, 300° F. (149° C.), and80 PSI. This seal received two to three activations with the sealer.

The bag was folded about 5.5 inches (about 14 cm) from (and parallel to)the bottom seal of the bag that was just made. Holding the bag partiallyfolded, with both ends up, 69.5 grams of corn kernels were poured intothe bag through its top. Next, a mixture of 5 grams of partiallyhydrogenated soybean oil and 2 grams of powdered salt was added to thebag. The top of the bag was sealed with one activation of the heatsealer for 0.6 seconds at 300° F. (149° C.), and 80 PSI.

When cooked in a 1200 watt microwave, oven the containment pouch burstafter approximately 19 to 35 seconds of exposure to microwave energy,the first popcorn kernel popped at about 40 to 58 seconds, the total poptime was from 1 minute 57 seconds to 2 minutes 17 seconds, and the popvolume averaged 3007 ml.

Comparative Example—Three bags of a commercially available popcornproduct (Orville Redenbacher's Butter flavor) were popped. The firstkernel popped at 46 seconds, the pop time averaged 1 minute 40 seconds,and the pop volume averaged 3150 ml.

EXAMPLE 2

Example 2 was a popcorn product incorporating a single cell containmentpouch for containment of trans-fat free oil and popcorn kernels. Fourcontainment pouches were made and tested using a similar procedure andthe same materials as described in Example 1, except as noted.

Containment pouches, 5.0 inches×5.5 inches (12.7 cm×14 cm) were made bythe same procedure as in Example 1. 69.5 grams of corn kernels werepoured into the pouch. Next, 22.05 grams of liquid oil were added to thepouch; again, care was taken not to contaminate the seal area with theoil. The fourth and final seal was made using the same technique aspreviously. The seal was slit and the opposite side was glued.

The containment pouch was positioned and secured to a bag in the samemanner as in Example 1. The bag was folded about 5.5 inches (about 14cm) from (and parallel to) the bottom seal of the bag that was justmade. Holding the bag partially folded, with both ends up, 5 grams ofpartially hydrogenated soybean oil and 2.75 grams of powdered salt werepoured into the bag through its top. The bag was sealed as describedabove.

Two-week old bags were placed in a medium (1100 watt) wattage microwaveoven. The average pop time was 2 minutes 30 seconds, and the average popvolume was 3088 ml. There was no off flavor, and there was no loss ofcrispiness of the popped corn.

The foregoing description, which has been disclosed by way of the aboveexamples and discussion, addresses embodiments of the present disclosureencompassing the principles of the present invention. The embodimentsmay be changed, modified and/or implemented using various types ofarrangements. Those skilled in the art will readily recognize variousmodifications and changes which may be made to the present inventionwithout strictly following the exemplary embodiments and applicationsillustrated and described herein, and without departing from the scopeof the present invention which is set forth in the following claims. Allpatents referred to herein are incorporated by reference herein in theirentirety.

1. A microwave popcorn product comprising: (a) an outer flexiblemicrowaveable expandable bag; (b) unpopped popcorn kernels within theexpandable bag; (c) an internal containment package positioned withinthe expandable bag, the internal containment package having a first celland a second cell, the first cell positioned within the second cell; (d)said first cell containing substantially only a liquid component, saidliquid component consisting essentially of free water and salt containedwith the first cell in an amount sufficient to burst the first cell, andthen the second cell, upon microwave heating of said expandable bag withsaid internal containment package contained therein; and (e) an oil/fatcomponent contained within the second cell external to the first cell;the internal containment package constructed and arranged, due to theincrease of pressure therein during a microwave heating process, toburst, and release the oil/fat component contained therein, into saidexpandable bag; wherein the internal containment package is disposed ina position substantially adjacent to the unpopped popcorn kernels, atleast a portion of which are external to the containment package, andwherein the internal containment package is unattached to a surface ofthe expandable bag.
 2. The popcorn product according to claim 1, whereinthe unpopped popcorn kernels are present external to the containmentpackage.
 3. The popcorn product according to claim 2, wherein theoil/fat component comprises a trans-fat free oil/fat.
 4. The popcornproduct according to claim 3, wherein the oil/fat component comprisesthe trans-fat free oil/fat and a trans oil/fat, the trans-fat freeoil/fat being contained in the containment package and the trans-fatoil/fat being present in the expandable package external to thecontainment package.
 5. The popcorn product according to claim 4,wherein the trans oil/fat comprises no more than 10 wt-% of the oil/fatcomponent.
 6. The popcorn product according to claim 5, wherein thetrans oil/fat comprises no more than 5 wt-% of the oil/fat component. 7.The popcorn product according to claim 4, wherein the popcorn kernelsare present in the expandable bag external to the containment package.8. The popcorn product according to claim 7, wherein all the popcornkernels are present external to the containment package.
 9. The popcornproduct according to claim 1, wherein the salt and water are present asa saline solution of no more than about 13% salt.
 10. The method ofclaim 1, wherein an outer surface of said internal containment packagecomprises a heat activated adhesive; said internal containment packagearranged to adhere to an inside surface of said expandable bag uponmicrowave heating of said expandable bag.
 11. A microwave popcornproduct comprising: (a) an outer microwaveable, expandable package; (b)unpopped popcorn kernels within the expandable package; (c) an internalcontainment package positioned within the expandable package, theinternal containment package having a first cell and a second cell, thefirst cell positioned within the second cell; (d) said first cellcontaining substantially only a liquid component, said liquid componentconsisting essentially of free water and salt contained within the firstcell, said liquid component being present in an amount sufficient toburst the first cell, and then the second cell, upon microwave heatingof said expandable package with said internal containment packagecontained therein; and (e) an oil/fat component contained within thesecond cell external to the first cell; the internal containment packageconstructed and arranged, due to the increase of pressure therein duringa microwave heating process, to burst and release the oil/fat componentcontained therein into said expandable package; wherein the internalcontainment package is disposed in a position substantially adjacent tothe unpopped popcorn kernels, at least a portion of which are externalto the containment package; and wherein the internal containment packageis unattached to a surface of the expandable package.
 12. The popcornproduct according to claim 11, wherein the microwaveable package is aflexible microwaveable bag configured for expansion.
 13. The popcornproduct according to claim 11, wherein the oil/fat component comprises atrans-fat free oil/fat.
 14. The method of claim 11, wherein an outersurface of said internal containment package comprises a heat activatedadhesive; said internal containment package arranged to adhere to aninside surface of said expandable bag upon microwave heating of saidexpandable bag.
 15. A microwave popcorn product comprising: (a) an outerflexible microwaveable expandable bag; (b) unpopped popcorn kernelswithin the expandable bag; (c) an internal containment packagepositioned within the expandable bag, the internal containment packagehaving a first cell and a second cell, the first cell positioned withinthe second cell; (d) said first cell containing substantially only aliquid component, said liquid component consisting essentially of freewater and salt contained with the first cell in an amount sufficient toburst the first cell, and then the second cell, upon microwave heatingof said expandable bag with said internal containment package containedtherein; and (e) an oil/fat component contained within the second cellexternal to the first cell; the internal containment package constructedand arranged, due to the increase of pressure therein during a microwaveheating process, to burst, and release the oil/fat component containedtherein, into said expandable bag; wherein the internal containmentpackage is disposed in a position substantially adjacent to the unpoppedpopcorn kernels, at least a portion of which are external to thecontainment package, and wherein the internal containment package issealed or attached into an end seam or side seam of the expandable bag.16. The popcorn product according to claim 15, wherein the microwaveablepackage is a flexible microwaveable bag configured for expansion. 17.The popcorn product according to claim 15, wherein the oil/fat componentcomprises a trans-fat free oil/fat.